Power tool operation recording and playback

ABSTRACT

A power tool and method for recording and playing back a motor parameter. The power tool includes a housing, a motor, a trigger, and a controller. The trigger outputs an activation signal based on a user input. The controller receives a user mode selection signal indicating a selected mode. The controller enters the recording mode when the user mode selection indicates the recording mode, and records a motor parameter to generate a recorded motor parameter. The recorded motor parameter covers a first time period in which motor is operating in response to depression of the trigger, a second time period in which motor is inactive in response to release of the trigger, and a third time period in which motor is operating in response to another depression of the trigger. In the playback mode, the controller operates the motor based on the recorded motor parameter upon receiving the activation signal.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/563,466, filed Dec. 28, 2021, which is a continuation of U.S. patentapplication Ser. No. 15/656,950, filed Jul. 21, 2017, which is acontinuation of U.S. patent application Ser. No. 14/213,098, filed Mar.14, 2014, which claims priority to U.S. Provisional Patent ApplicationNo. 61/788,510, filed on Mar. 15, 2013, the entire contents of both ofwhich are incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates generally to power tools, such as powerdrills or impact drivers.

SUMMARY

In one embodiment, the invention provides a power tool including a toolhousing defining a cavity, a motor positioned within the cavity, atrigger, a mode selector switch, and a controller. The trigger iscoupled to the tool housing and configured to output an activationsignal based on a user input. The mode selector switch is configured toreceive a user mode selection, which indicates an operating modeselected from the group of a recording mode, a normal operating mode,and a playback mode. The controller is coupled to the trigger, the modeselector switch, and the motor. The controller is configured to receivea mode selection signal from the mode selector switch that is indicativeof the user mode selection for the power tool. The controller is furtherconfigured to enter the recording mode when the user mode selectionindicates the recording mode, and to record a motor parameter while thepower tool is in the recording mode and the motor is operating togenerate a recorded motor parameter. The controller is furtherconfigured to enter the playback mode when the user mode selectionindicates the playback mode, and to operate the motor based on therecorded motor parameter upon receiving the activation signal from thetrigger while the power tool is in the playback mode.

In another embodiment, the invention provides a method of operating apower tool including a motor, a mode selector switch, a trigger, and acontroller. The method includes receiving, by the mode selector switch,a user mode selection indicating an operating mode for the power tool.The operating mode is selected from the group of a recording mode, aplayback mode, and a normal operating mode. The method further includesentering, by the controller, the recording mode when the user modeselection indicates the recording mode, and recording, by thecontroller, a motor parameter while the power tool is in the recordingmode and the motor is operating to generate a recorded motor parameter.The method further includes entering, by the controller, the playbackmode when the user mode selection indicates the playback mode, andreceiving, by the controller, an activation signal from the trigger. Themethod further includes executing, by the controller, the recorded motorparameter to operate the motor based on the recorded motor parameterupon receipt of the activation signal while the power tool is in theplayback mode.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a tool according to one embodiment ofthe invention.

FIG. 2 is a side view of the tool shown in FIG. 1 with a portion of atool housing removed.

FIG. 3 illustrates a direction switch of the tool shown in FIG. 1 in aFORWARD position.

FIG. 4 illustrates the direction switch of the tool shown in FIG. 1 in aREVERSE position.

FIG. 5 illustrates the direction switch of the tool shown in FIG. 1 in aNEUTRAL position.

FIG. 6 illustrates a speed selector switch of the tool shown in FIG. 1 .

FIG. 7 illustrates a block diagram of the speed selector switch shown inFIG. 6 .

FIG. 8 is an electrical schematic diagram of the tool shown in FIG. 1 ,and including a controller.

FIG. 9 is an operational schematic diagram of the tool shown in FIG. 1 .

FIG. 10 is an operational schematic diagram of the tool shown in FIG. 1.

FIG. 11 an operational schematic diagram of the tool shown in FIG. 1 .

FIG. 12 an operational schematic diagram of the tool shown in FIG. 1 .

FIG. 13 an operational schematic diagram of the tool shown in FIG. 1 .

FIG. 14 an operational schematic diagram of the tool shown in FIG. 1 .

FIG. 15 is a perspective view of the tool shown in FIG. 1 with the toolhousing removed.

FIG. 16 is a perspective view of the tool shown in FIG. 1 with a motorand a portion of the tool housing removed.

FIG. 17 is a perspective view of a tool according to another embodimentof the invention.

FIG. 18 is a side view of the tool shown in FIG. 17 .

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

In one embodiment, the invention provides a power tool that includes atool housing defining a cavity and a pocket formed in a wall of the toolhousing. A motor is positioned within the cavity, and a triggermechanism is moveably coupled to the tool housing. A mode selectorswitch is positioned within the pocket, the mode selector switchincluding a plurality of speed indicators and a push-button operable toreceive a user mode selection. The mode selector switch is operable toallow the power tool to be operated in one of a recording mode, aplayback mode, and a normal operating mode based on the user modeselection, and the speed indicators indicate the user mode selection.The power tool further includes a controller operable to receive theuser mode signal from the speed selector switch, the user mode signalindicative of a selected user mode, receive an activation signal fromthe trigger switch, record operation of a motor or other parameterduring the recording mode upon receiving the activation signal, operatethe motor during the playback mode based on the recorded motor operationupon receiving the activation signal, or operate the motor according tothe activation signal during the normal operating mode. While theembodiments described hereinbelow refer to motor parameter recording,embodiments of the invention contemplate the recording and playback ofother operating parameters as well that result from activation of thetrigger, and references to “motor parameter” are not intended to belimiting to only parameters directly related to operation of the motor.

In another embodiment, the invention provides a power tool including atool housing defining a cavity, a motor positioned within the cavity,and a trigger mechanism moveably coupled to the tool housing. A usagemode selector switch is coupled to the tool housing, and the toolincludes a plurality of usage mode indicators. The usage mode selectorswitch is operable to receive a usage mode selection selecting one of arecording mode, a playback mode, and a normal use mode. The usage modeselector switch is operable to output a usage mode signal based on theusage mode selection, and the usage mode indicators indicate the usagemode selection. The power tool also includes a controller operable toreceive the usage mode signal from the usage mode selector switch, theusage mode signal indicative of a selected usage mode. The controllerreceives an activation signal from the trigger switch, records anoperation of the motor during the recording mode upon receiving theactivation signal, plays back a recorded operation of the motor duringthe playback mode upon receiving the activation signal, and operates themotor according to the activation signal during the normal use mode.

FIG. 1 is a perspective view of a power tool 100 (e.g., a power drill,an impact driver, a power saw, an angle driver, etc.). The tool 100includes a tool housing 105 defining a body portion 110 and a handle115. The body portion 110 of the tool housing 105 includes a top surface120, a bottom surface 125, side surfaces 130, 135, a front surface 140,and a rear surface 145. FIG. 2 illustrates the tool 100 with a portionof the tool housing 105 removed. The tool housing 105 further includes awall 150 defining an exterior surface 155 and an interior surface 160 ofthe housing 105. The interior surface 160 defines a cavity 162 withinthe body portion 110.

In one embodiment, a user mode selector switch 165 is disposed betweenthe exterior surface 155 and the interior surface 160 of the wall 150and within a pocket 170 defined by the wall 150. In the illustratedembodiment, the pocket 170 is located proximately to the cavity 162, andthe user mode selector switch 165 is accessible from the top surface 120of the housing 105. In other embodiments, the user mode selector switch165 is accessible via another surface of the housing, such as one of theside surfaces 130, 135 or the rear surface 145. A printed circuit board(PCB) 175 and a motor 180 are located within the cavity 162 of the bodyportion 110. The motor 180 is coupled to the interior surface 160 via amotor mount 185.

In the illustrated embodiment, the handle 115 extends downwardly fromthe bottom surface 125 of the body portion 110 such that the tool 100has a pistol-style grip. A battery receptacle 190 is located at a distalend of the handle 115, and a trigger mechanism 195 is positioned on thehandle 115 proximate the body portion 110. In an alternative embodiment,the user mode selector switch 165 may be accessible via a surface of thehandle 115 such as a position below trigger mechanism 195 and adjacentto the battery receptacle 190.

The PCB 175 is electrically coupled to the motor 180 and includeselectrical and electronic components that are operable to control thetool 100. In the illustrated embodiment, the PCB 175 includes acontroller 200 (FIG. 8 ) for controlling operation of the tool 100.

The motor 180 is a multi-speed, brushless direct-current (BLDC) motor.As is commonly known, BLDC motors include a stator, a permanent magnetrotor, and an electronic commutator. The electronic commutator typicallyincludes, among other things, a programmable device (e.g., amicrocontroller, a digital signal processor, or a similar controller)having a processor and a memory. The programmable device of the BLDCmotor uses software stored in the memory to control the electriccommutator. The electric commutator then provides the appropriateelectrical energy to the stator in order to rotate the permanent magnetrotor at a desired speed. In some embodiments, the controller 200 actsas the programmable device of the motor 180. In other embodiments, theprogrammable device is separate from the controller 200. In otherembodiments of the motor 180, the motor 180 can be a variety of othertypes of multi-speed or variable-speed motors, including but not limitedto, a brush direct-current motor, a stepper motor, a synchronous motor,an induction motor, a vector-driven motor, a switched reluctance motor,and other DC or AC motors. The motor 180 is used to drive a workingelement 205 (FIG. 2 ). In the illustrated embodiment, the workingelement 205 is located on the front surface 140 of the body portion 110.In the illustrated embodiment the working element 205 is a drill chuck,but other types of tools, such as angle grinders, saws, etc., will usedifferent working elements.

The battery receptacle 190 receives a battery 210 (FIG. 8 ), whichprovides power to the tool 100. In some embodiments, the battery 210 isa rechargeable lithium-ion battery. In other embodiments, the battery210 may have a chemistry other than lithium-ion such as, for example,nickel cadmium, nickel metal-hydride, etc. Additionally oralternatively, the battery 210 may be a non-rechargeable battery. Insome embodiments, the battery 210 is a power tool battery including apack housing containing one or more battery cells and a latchingmechanism for selectively securing the battery 210 to the batteryreceptacle 190. In another embodiment, the battery 210 is mountedexternally to the handle 115. In another embodiment, the battery 210 ismounted below the handle 115. In another embodiment, an electrical cordprovides power to the tool 100.

Referring to FIGS. 2-6 , the trigger mechanism 195 includes a trigger215, a direction switch 220, and an electrical switch 225. In theillustrated embodiment, the trigger 215 extends partially down a lengthof the handle 115; however, in other embodiments the trigger 215 extendsdown the entire length of the handle 115 or may be positioned elsewhereon the tool 100. The trigger 215 is moveably coupled to the handle 115such that the trigger 215 moves with respect to the tool housing 105.The trigger 215 includes an interior portion 230 and an exterior portion235, which is accessible to the user. The interior portion 230 iscoupled to a push rod 240, which is engageable with the electricalswitch 225. The exterior portion 235 of the trigger 215 moves in a firstdirection 245 towards the handle 115, when the trigger 215 is depressedby the user. The exterior portion 235 moves in a second direction 250,away from the handle 115, when the trigger 215 is released by the user.When the trigger 215 is depressed by the user, the push rod 240activates the electrical switch 225, and when the trigger 215 isreleased by the user, the electrical switch 225 is deactivated.

In the illustrated embodiment, the electrical switch 225 is apush-button electrical switch positioned within the handle 115. Theelectrical switch 225 includes a push button 255 and electricalcontacts. When the push button 255 is activated, such as by the push rod240, the electrical contacts are in a CLOSED position. When theelectrical contacts are in the CLOSED position, electrical current issupplied from the battery to the motor 180, via the controller 200. Whenthe push button 255 is not activated, the electrical contacts are in theOPEN position. When the electrical contacts are in the OPEN position,electrical current is not supplied from the battery to the motor 180.Although the electrical switch 225 is illustrated as a push-buttonelectrical switch with contacts, other types of electrical switches maybe used with the tool 100.

The direction switch 220 is located above the trigger 215 and below thebody portion 110 of the tool 100. The direction switch 220 is slidinglycoupled to the handle 115. As shown in FIGS. 3-5 , the direction switch220 includes a first side 260 and a second side 265. The directionswitch 220 controls the directional mode of operation of the motor 180(e.g., FORWARD, REVERSE, and NEUTRAL) by sending a signal, based on theposition of the direction switch 220, to the controller 200. As shown inFIG. 3 , when the first side 260 of the direction switch 220 is fullydepressed, the direction switch 220 is in a first position. When thedirection switch 220 is in the first position, the mode of operation formotor 180 is in the FORWARD direction. As shown in FIG. 4 , when thesecond side 265 of the direction switch 220 is fully depressed, thedirection switch 220 is in a second position, the second position beingopposite the first position. When the direction switch 220 is in thesecond position, the mode of operation of the motor 180 is in theREVERSE direction. As shown in FIG. 5 , when the direction switch 220 isin a third position, neither the first side 260 or second side 265 isfully depressed, and the mode of operation of the motor 180 is NEUTRAL.

As discussed above, the tool 100 includes the user mode selector switch165, as shown in more detail in FIGS. 6 and 7 according to oneembodiment. The user mode selector switch 165 is a multi-layerelectrical switch including a label layer 270, a push-button 275, aprinted circuit board layer 280, and light-emitting diodes (LEDs) 285,290. The label layer 270 includes mode indicators 295, 300. Modeindicator 295 indicates to the operator, for example, that a recordingmode is selected, and mode indicator 300 indicates to the operator, forexample, that a playback mode is selected. When both indicators 295 and300 are off, the normal use mode of the tool is selected. Thepush-button 275 is an electrical push-button, and in the illustratedembodiment, the push-button 275 is a low-profile pop-switch. In someembodiments, the printed circuit board layer 280 includes a controllerhaving a similar construction as controller 200.

According to another embodiment, the user mode selector switch 165 ispositioned below trigger mechanism 195 and adjacent to the batteryreceptacle 190 (an example of which is shown in FIGS. 17 and 18 ). Aplurality of mode indicators 301, 302, and 303, indicate to the operatorthe recording, playback, and normal user modes of the tool 100. The usermode selector switch 165 may be a multi-layer electrical switch such asthat described above. Alternatively, tool 100 may have a singleindicator, such as indicator 301, to indicate the recording, playback,and normal user modes. The indicator may indicate the recording mode,for example, using a blinking indicator signal. The playback mode may beindicated, for example, by a constant-on indicator signal. When theindicator 301 is off, the normal user mode may be indicated. One skilledin the art will recognize that the number of indicators and the mannerof their visual display according to other embodiments are within thescope of the present invention.

In operation, the user mode selector switch 165 controls the operatingmode of the motor 180, via the controller 200, allowing the operator tochoose between the recording, playback, and normal user modes. When thepush-button 275 is pressed, the user modes are selected. The LEDs 285,290 illuminate the mode indicators 295, 300, or indicators 301-303 areilluminated, to indicate to the operator the currently selectedoperating mode of the motor 180.

FIG. 8 is an electrical schematic of the tool 100 including thecontroller 200. The controller 200 is electrically and/orcommunicatively connected to a variety of modules or components of thetool 100. For example, the controller 200 is electrically connected tothe battery 210, the motor 180, the user mode selector switch 165,components of the trigger mechanism 195 (i.e., the electrical switch 225and the direction switch 220), as well as other components of the tool100. The controller 200 includes combinations of hardware and softwarethat are operable to, among other things, control the operation of thetool 100. In some embodiments, the controller 200 includes electricaland electronic components that provide power, operational control, andprotection to the components and modules within the controller 200 andtool 100. For example, the controller 200 includes, among other things,a processor 202 (e.g., a microprocessor, a microcontroller, or anothersuitable programmable device) and a memory 203.

The memory 203 includes, for example, a program storage and a datastorage. The program storage and the data storage can includecombinations of different types of memory, such as read-only memory(“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”],synchronous DRAM [“SDRAM”], etc.), electrically erasable programmableread-only memory (“EEPROM”), flash memory, a hard disk, an SD card, orother suitable magnetic, optical, physical, or electronic memorydevices. The processor 202 is connected to the memory 203 and executessoftware instructions that are capable of being stored in a RAM of thememory 203 (e.g., during execution), a ROM of the memory 203 (e.g., on agenerally permanent basis), or another non-transitory computer readablemedium such as another memory or a disc. Software included in theimplementation of the tool 100 can be stored in the memory 203 of thecontroller 200. The software includes, for example, firmware, one ormore applications, program data, filters, rules, one or more programmodules, and other executable instructions. The controller 200 isconfigured to retrieve from memory and execute, among other things,instructions related to the control processes and method describedherein. In other embodiments, the controller 200 includes additional,fewer, or different components.

The controller 200 is electrically coupled to the user mode selectorswitch 165, the motor 180, the electrical switch 225 and the directionswitch 220 of the trigger mechanism 195, and the battery 210, throughthe battery receptacle 190. The controller 200 receives signals from theelectrical components of the tool 100 and controls operation of the tool100 according to the received signals.

In one embodiment of operation, a user selects an operating mode usingthe user mode selector switch 165. The user mode selector switch 165sends a first mode signal, a second mode signal, or a third mode signalto the controller 200. The user then selects a FORWARD direction, aREVERSE direction, or NEUTRAL using the direction switch 220. Thedirection switch 220 sends a direction signal to the controller 200.Once the user activates the trigger mechanism 195, the electrical switch225 of the trigger mechanism 195 sends an activation signal to thecontroller 200. The controller operates the motor 180 upon receiving theactivation signal according to the user mode that is selected.

FIG. 9 illustrates a pulse diagram 400 for an operation of thecontroller 200 during a recording mode according to an embodiment of theinvention. The controller 200 receives a user mode signal from the usermode selector switch 165 and begins the recording mode at 405. Accordingto the embodiment illustrated in FIG. 9 , the recording mode comprises atimed mode in which data from the desired motor parameter is measuredand recorded from the start of the record mode until the end of therecord mode, which may be a specific time period 410 or may be ended bythe user changing the user mode to the playback mode or to the normaluse mode. In the timed mode, data for the desired motor parameter ismeasured whether or not there is an activation signal from the triggermechanism 195. Accordingly, during periods in which there is no triggeractivation that causes activation of the motor, the data for the desiredrecorded motor parameter is measured and recorded even if the measureddata results in values that do not cause activation of the motor.

As illustrated in FIG. 9 , the start of record mode 405 begins recordingthe usage of the motor parameter prior to receiving an activation signalfrom the trigger assembly. When the trigger assembly is activated at412, the motor parameter signal 415 that is changed thereby is measuredand recorded during the recording of the usage. The resulting recordedmotor parameter signal 420 is stored and used during playback asdescribed herein below. The recorded motor parameter signal 420 may bestored in its entirety including the blank or null portions for which nomotor control parameter was manipulated or recorded during the recordmode or may be truncated to the portion 425 for which the motor controlparameter signals 415 were recorded during the record mode. Thetruncation may occur after recording for storage and later playback ormay be truncated during the playback mode.

According to embodiments of the invention, the motor parameter signals415 that are measured and recorded during the record mode may includePWM duty cycle (amount of trigger pull), the speed of the motor, thetorque of the motor, the power to the motor, the number of impact“blows”, and other motor parameters.

FIG. 10 illustrates a pulse diagram 430 for an operation of thecontroller 200 during a recording mode according to another embodimentof the invention. The controller 200 receives a user mode signal fromthe user mode selector switch 165 to begin the recording mode at 405,but does not begin recording the usage of the motor parameter signal 415until activation of the trigger begins at 412. According to theembodiment illustrated in FIG. 10 , the recording mode comprises a timedmode in which data from the motor parameter signal 415 is measured andrecorded from the start of the trigger activation at 412 until the endof the record mode 405, which may be a specific time period 410 or maybe ended by the user changing the user mode to the playback mode or tothe normal use mode. In this mode, data for the motor parameter signal415 is measured beginning from when the trigger is first activated at412 and continues whether or not there is an activation signal from thetrigger mechanism 195 until the end of the recording mode 405 (e.g., theend of the time period 410). Accordingly, during periods in which thereis no trigger activation (e.g., time period 435) that causes activationof the motor once recording has begun, the data for the desired recordedmotor parameter is measured and recorded even if the measured dataresults in values that do not cause activation of the motor.

As illustrated in FIG. 10 , the start of record mode 405 beginsrecording the usage of the motor parameter signal 415 at the firstactivation of the trigger assembly at 412. When the trigger assembly isactivated, the motor parameter signal 415 that is changed thereby ismeasured and recorded during the recording of the usage. Since recordingcontinues after the first trigger activation at 412 even when there isno activation of the trigger (e.g., during period 435), subsequenttrigger activation pulses 440 and 445 are also recorded, which may occurthrough a user's preference of pulsing an impact tool, for example,after seating a fastener. The resulting recorded motor parameter signal420 is stored and used during playback as described herein below. Therecorded motor parameter signal 420 may be stored in its entiretyincluding the blank or null portions for which no motor controlparameter was manipulated or recorded during the record mode or may betruncated to the portion 425 for which motor control parameter signals415 were recorded during the record mode 405. The truncation may occurafter recording for storage and later playback or may be truncatedduring the playback mode.

FIG. 11 illustrates a pulse diagram 450 for an operation of thecontroller 200 during a recording mode according to another embodimentof the invention. The controller 200 receives a user mode signal fromthe user mode selector switch 165 to begin the recording mode at 405,but does not begin recording the usage of the motor parameter signal 415until activation of the trigger begins at 412. According to theembodiment illustrated in FIG. 11 , the recording mode comprises atrigger-recording mode in which data from the motor parameter signal 415is measured and recorded from the start of the trigger activation at 412until the end of the single trigger activation event at 452. In thismode, data for the motor parameter signal 415 is measured beginning fromwhen the trigger is first activated at 412 and terminates when theactivation signal from the trigger mechanism 195 is first ended at 452.Accordingly, the data for the motor parameter signal 415 is measured andrecorded only during the first, single trigger activation signal.

As illustrated in FIG. 11 , the start of record mode 405 beginsrecording the usage of the motor parameter signal 415 at the firstactivation of the trigger assembly at 412. When the trigger assembly isactivated at 412, the motor parameter signal 415 that is changed therebyis measured and recorded during the recording of the usage. Sincerecording stops after the first trigger activation, subsequent triggeractivation pulses are not recorded. The resulting recorded motorparameter signal 420 is stored and used during playback as describedherein below.

According to an embodiment of invention, the playback mode of the toolmay be automatically set and entered into at the end of the recordingmodes 405 illustrated in FIGS. 9-11 .

FIG. 12 illustrates a pulse diagram 460 for an operation of thecontroller 200 during a playback mode according to another embodiment ofthe invention. As an example, the recorded motor parameter signal 420 ofFIG. 10 is used for the pulse diagram 460 of FIG. 12 . The controller200 receives a user mode signal from the user mode selector switch 165to begin the playback mode 465 but does not begin executing the recordedmotor parameter signal 420 until activation of the trigger begins at470.

As illustrated, activation of the trigger at 470 begins execution (orplayback) of the recorded motor parameter signal 420 according to whatwas recorded and stored during the recording mode 405 of pulse diagram430. While the trigger activation pulse 470 does not match the executedrecorded motor parameter signal 420, execution of the recorded motorparameter signal 420 allows for repeatability of the recorded parametereven when the trigger activation signal 470 does not match. Accordingly,a different trigger activation signal profile nevertheless causes therecorded motor parameter signal 420 to be executed. In this manner, therecorded motor parameter signal 420 may be reliably repeated for taskssuch as motor line assembly scenarios or other such tasks wherepredictability of tool use is desired. As illustrated, when therecording time period 410 is ended, the executed recorded motorparameter signal 420 is also ended, and even though trigger activationsignal 470 illustrates that the trigger mechanism 195 is still beingactivated, the tool motor is not activated since the recorded motorparameter signal 420 has ended. The recorded motor parameter signal 420is not executed again until re-activation of the trigger mechanism 195 asubsequent time during playback mode 465 in one embodiment.

According to another embodiment of the invention, the recorded motorparameter signal 420 is repeatedly executed as long as the triggermechanism 195 is activated. In this manner, for example, a recordedparameter signal (e.g., the recorded motor parameter signal 420) thatoscillates the motor parameter between two or more values may continueto oscillate the motor parameter for a longer duration of the triggeractivation. As such, a short recorded signal may be extended and beexecuted many times repeatedly during a long trigger activation time.

FIG. 13 illustrates a pulse diagram 480 for an operation of thecontroller 200 during a playback mode according to another embodiment ofthe invention. As an example, the recorded motor parameter signal 420 ofFIG. 10 is used for the pulse diagram 480 of FIG. 13 . The controller200 receives a user mode signal from the user mode selector switch 165to begin the playback mode 465 but does not begin executing the recordedmotor parameter signal 420 until activation of the trigger begins at470.

As illustrated, however, at the end of a first trigger activation time485 that may be caused, for example, by the user releasing the triggermechanism 195, playback of the recorded motor parameter signal 420 ishalted when the trigger mechanism 195 is released. When the triggermechanism 195 is re-activated during a subsequent trigger activationsignal 490, the recorded motor parameter signal 420 is played back fromthe beginning during a second trigger activation time 495 even though itwas halted during the previous execution. In this manner, playback ofthe recorded motor parameter signal 420 is re-initiated from thebeginning each time the trigger mechanism 195 is re-activated.

FIG. 14 illustrates a pulse diagram 500 for an operation of thecontroller 200 during a playback mode according to another embodiment ofthe invention. As an example, the recorded parameter signal 420 of FIG.11 is used for the pulse diagram 500 of FIG. 14 . The controller 200receives a user mode signal from the user mode selector switch 165 tobegin the playback mode 465 but does not begin executing the recordedmotor parameter signal 420 until activation of the trigger begins at510. A direction signal from the direction switch 220 illustrates thatthe tool is in a forward mode direction 505 at the beginning of theplayback mode 465.

Similar to that illustrated in FIG. 12 , at the end of a first triggeractivation time 515 that may be caused, for example, by the userreleasing the trigger mechanism 195, playback of the recorded motorparameter signal 420 is halted when the trigger mechanism 195 isreleased. For example, the user may stop the trigger activation 510 inorder to switch the direction switch 220 to the reverse direction mode520 in order to engage a fastener to back it out of its current positionprior to re-engaging the fastener to drive it forward. During thereverse mode 520, the recorded motor parameter signal 420 is notexecuted, but instead, the trigger activation signal 525 at a time 530controls the motor according to a normal operating mode such that themotor parameter signal 535 executed during the reverse mode 520 directlycorresponds with the trigger activation signal 525. While playback mode465 is illustrated as continuing to be active throughout the directionchange into the reverse mode 520, playback mode 465 may be deactivatedas illustrated in phantom at 537 while the reverse mode 520 is engaged.When the forward mode 505 is re-engaged via direction switch 220 and thetrigger mechanism 195 is re-activated during a subsequent triggeractivation signal 540, the recorded motor parameter signal 420 is playedback from the beginning during a second trigger activation time 545 eventhough it was halted during the previous execution. In this manner,playback of the recorded motor parameter signal 420 is re-initiated fromthe beginning each time the trigger mechanism 195 is re-activated.

Referring to FIG. 15 , in the illustrated embodiment, the user modeselector switch 165 is located within the pocket 170 proximate to themotor 180 and accessible from the top surface 120 of the tool housing105. The compact design of the user mode selector switch 165 allows itto be placed in the relatively small space above the motor 180. Further,the lightweight design of the user mode selector switch 165 adds littleweight to the tool 100.

As shown in FIG. 16 , with the motor 180 removed for viewing purposes,wires 550 for the user mode selector switch 165 run along a side of theinterior surface 160 of the body portion 110 and electrically couple theuser mode selector switch 165 to the PCB 175.

The cordless, hand-held power tool illustrated in FIGS. 17-18 is animpact wrench 600. The impact wrench 600 includes an upper main body604, a handle portion 608, a battery pack receiving portion 612, usermode selector switch(es) 165, mode indicators 301-303, an output drivedevice or mechanism 616, a forward/reverse selection button 220, atrigger 215, and air vents 628. The impact wrench 600 also includes aworklight 632. The battery pack receiving portion 612 receives a portionof a battery pack and includes a terminal assembly including a pluralityof terminals. The number of terminals present in the receiving portion612 can vary based on the type of hand-held power tool. However, as anillustrative example, the receiving portion 612 and the terminalassembly can include a battery positive (“B+”) terminal, a batterynegative (“B−”) terminal, a sense or communication terminal, anidentification terminal, etc. The outer portions or housing of theimpact wrench 600 (e.g., the main body 604 and the handle portion 608)are composed of a durable and light-weight plastic material. The drivemechanism 616 is composed of a metal (e.g., steel) as is known in theart.

The battery positive and battery negative terminals are operable toelectrically connect the battery pack to the hand-held power tool andprovide operational power (i.e., voltage and current) for the hand-heldpower tool from the battery pack to the hand-held power tool. The sensoror communication terminal is operable to provide for communication orsensing for the hand-held power tool of the battery pack. For example,the communication can include serial communication or a serialcommunication link, the transmission or conveyance of information fromone of the battery pack or the hand-held power tool to the other of thebattery pack or hand-held power tool related to a condition orcharacteristic of the battery pack or hand-held power tool (e.g., one ormore battery cell voltages, one or more battery pack voltages, one ormore battery cell temperatures, one or more battery pack temperatures,etc.).

The identification terminal can be used by the battery pack or thehand-held power tool to identify the other of the battery pack or thehand-held power tool. For example, the hand-held power tool can identifythe battery pack as a high capacity battery pack or a normal capacitybattery pack, as a lithium-based battery or a nickel-based battery, as abattery pack having a particular voltage (described below), a higherresistance battery pack, a lower resistance battery pack, etc.Additionally or alternatively, the battery pack can identify thehand-held power tool as a hammer drill, a drill/wrench, an impactwrench, an impact wrench, a brushless power tool, a brushed power tool,a higher resistance power tool (e.g., capable of lower power output), alower resistance power tool (e.g., capable of higher power output), etc.

One of skill in the art will recognize that embodiments of the inventionmay be incorporated into tools such as power drills, impact drivers,power saws, angle drivers, and other tools incorporating auser-activated trigger mechanism. One skilled in the art will alsorecognize that the trigger activation signals, while illustrated asbeing discrete steps, are merely examples and that other continuoustypes of trigger activation signals are contemplated herein.

Thus, the invention provides, among other things, a power tool includinga speed selector switch for selecting an operating speed of the powertool. Various features and advantages of the invention are set forth inthe following claims.

What is claimed is:
 1. A power tool comprising: a tool housing defininga cavity; a motor positioned within the cavity; and a switch operable tocontrol a characteristic of the power tool, the switch including anactuable layer, a label layer, and a printed circuit board (PCB) layer,the actuable layer and the label layer provided over the PCB layer. 2.The power tool of claim 1, wherein the label layer includes a modeindicator for indicating a mode of the power tool.
 3. The power tool ofclaim 2, wherein the mode is one selected from a group consisting of arecording mode and a playback mode, wherein a parameter of the powertool is recorded in the recording mode, and wherein a recorded parameterof the power tool is repeated in the playback mode.
 4. The power tool ofclaim 2, wherein the switch includes a light emitting diode (LED)provided below the label layer, wherein the label layer and the LEDtogether indicate the mode.
 5. The power tool of claim 1, wherein thelabel layer includes a first mode indicator and a second mode indicator,wherein a push-button is provided on the actuable layer, and wherein thepush-button is provided between the first mode indicator and the secondmode indicator.
 6. The power tool of claim 5, wherein the switchincludes a first light emitting diode (LED) and a second LED providedbelow the label layer such that the first LED is positioned below thefirst mode indicator to illuminate the first mode indicator and thesecond LED is positioned below the second mode indicator to illuminatethe second mode indicator.
 7. The power tool of claim 1, wherein thetool housing includes an exterior surface and an interior surface,wherein the interior surface defines the cavity, and wherein the switchis disposed between the exterior surface and the interior surface.
 8. Apower tool comprising: a tool housing defining a cavity; a motorpositioned within the cavity; a printed circuit board (PCB) provided inthe cavity; a switch operable to control a characteristic of the powertool, the switch including an actuable layer provided over a printedcircuit board (PCB) layer; and a wire electrically coupling the switchto the PCB.
 9. The power tool of claim 8, wherein a first controller isprovided on the PCB and a second controller is provided on the PCBlayer.
 10. The power tool of claim 8, wherein the PCB and the switch areprovided on opposite sides of the motor.
 11. The power tool of claim 8,wherein the wire is routed along an outer surface of the motor betweenthe switch and the PCB.
 12. The power tool of claim 8, wherein the PCBincludes a first planar surface and the PCB layer includes a secondplanar surface, wherein the first planar surface and the second planarsurface are parallel to a rotational axis of the motor.
 13. The powertool of claim 8, wherein the tool housing includes a body portion and ahandle, the cavity defined by the body portion and the handle extendingfrom the body portion, wherein the switch is provided on the bodyportion adjacent the motor.
 14. A power tool comprising: a tool housingdefining a cavity; a motor positioned within the cavity; and a switchoperable to control a characteristic of the power tool, the switchincluding an actuable layer provided over a printed circuit board (PCB)layer.
 15. The power tool of claim 14, wherein the actuable layerincludes a push-button.
 16. The power tool of claim 14, wherein the toolhousing includes an exterior surface and an interior surface, whereinthe interior surface defines the cavity, and wherein the switch isdisposed between the exterior surface and the interior surface.
 17. Thepower tool of claim 14, wherein the tool housing defines a pocketproximate the cavity, wherein the switch is located within the pocket.18. The power tool of claim 14, wherein the switch is actuable to selectbetween a playback mode and a recording mode, the power tool furthercomprising: a controller electrically connected to the motor and theswitch, the motor configured to: receive, from the switch, a firstselection of the playback mode, enter the playback mode in response toreceiving the first selection, and operate the motor based on a recordedmotor parameter while the power tool is in the playback mode.
 19. Thepower tool of claim 18, wherein the controller is configured to:receive, from the switch, a second selection of the recording mode,enter the recording mode in response to receiving the second selection,and record a motor parameter based on an operation of the motor togenerate the recorded motor parameter.
 20. The power tool of claim 19,wherein the switch includes a label layer and a light emitting diode(LED) provided below the label layer, wherein the label layer includes amode indicator, wherein the controller is electrically connected to theLED and is configured to provide, using the LED, a mode indication of atleast one selected from the group consisting of the recording mode andthe playback mode.